The present invention relates to risers, and specifically methods of repair thereof and apparatuses used in the repair thereof.

Background of the Invention

There is increasing demand in the oil and gas industry to develop equipment and methods to enable subsea riser repair. Often, the aging risers to be repaired are disposed in deep water, making them inaccessible to divers. Furthermore, increasing restrictions on the use of divers is making riser repair, even in shallow water, increasingly challenging. Thus efforts are being made to develop techniques for deep water riser repair, utilizing apparatuses which can be hydraulically controlled from a remotely operated vehicle (ROV). The techniques must by design also be sensitive to the often fragile nature of the risers, as well as incorporating contingency measures in the event of a failed repair effort.

An objective of the present invention is to provide pipeline repair tools and methods which can be applied in deep water settings. Summary

Apparatuses for achieving the above objective are set out in independent claims 1 and 9. Methods for achieving the above objective are set out in independent claims 16, 23 and 32. Brief Description of the Drawings

Some embodiments of the invention will now be described by way of example only and with reference to the accompanying drawings, in which:

Figure 1 shows an alignment, installation and activation apparatus according to an embodiment of the invention;

Figure 2 shows an alignment, installation and activation apparatus according to an embodiment of the invention;

Figure 3 shows an alignment, installation and activation apparatus according to an embodiment of the invention; Figure 4 shows an alignment, installation and activation apparatus according to an embodiment of the invention;

Figure 5 shows an alignment, installation and activation apparatus according to an embodiment of the invention;

Figure 6 shows an alignment, installation and activation apparatus according to an embodiment of the invention;

Figure 7 shows an alignment, installation and activation apparatus according to an embodiment of the invention;

Figure 8 shows an alignment, installation and activation apparatus according to an embodiment of the invention;

Figure 9 shows an alignment, installation and activation apparatus according to an embodiment of the invention;

Figure 10 shows an alignment, installation and activation apparatus according to an embodiment of the invention;

Figure 1 1 shows an alignment, installation and activation apparatus according to an embodiment of the invention;

Figure 12 shows an alignment, installation and activation apparatus according to an embodiment of the invention;

Figure 13 shows an alignment, installation and activation apparatus according to an embodiment of the invention;

Figure 14 shows a gripper unit apparatus according to an embodiment of the invention;

Figure 15 shows a gripper unit apparatus according to an embodiment of the invention;

Figure 16 shows a gripper unit apparatus according to an embodiment of the invention;

Figure 17 shows a gripper unit apparatus according to an embodiment of the invention; Figure 18 shows a gripper unit apparatus according to an embodiment of the invention;

Figure 19 shows a gripper unit apparatus according to an embodiment of the invention;

Figure 20 shows a gripper unit apparatus according to an embodiment of the invention;

Figure 21 shows a gripper unit apparatus installation tool according to an embodiment of the invention;

Figure 22 shows a gripper unit apparatus installation tool according to an embodiment of the invention;

Figure 23 shows a method step according to an aspect of the invention;

Figure 24 shows a method step according to an aspect of the invention;

Figure 25 shows a method step according to an aspect of the invention;

Figure 26 shows a method step according to an aspect of the invention; Figure 27 shows a method step according to an aspect of the invention;

Figure 28 shows a method step according to an aspect of the invention;

Figure 29 shows a method step according to an aspect of the invention;

Figure 30 shows a method step according to an aspect of the invention;

Figure 31 shows a method step according to an aspect of the invention;

Figure 32 shows a method step according to an aspect of the invention;

Figure 33 shows a method step according to an aspect of the invention;

Figure 34 shows a method step according to an aspect of the invention;

Figure 35 shows a method step according to an aspect of the invention;

Figure 36 shows a method step according to an aspect of the invention;

Figure 37 shows a method step according to an aspect of the invention;

Figure 38 shows a method step according to an aspect of the invention;

Figure 39 shows a method step according to an aspect of the invention. Detailed Description of the Preferred Embodiments

A gripper unit apparatus (GU); alignment, installation and activation (AIA) apparatus; and several methods of use thereof are described in detail below, by way of example, and with reference to the accompanying drawings. Alignment installation and activation (AIA) apparatus:

According to an exemplary embodiment, the AIA apparatus 100, illustrated in Figure 1 , comprises the following principal components:

- Grabber bars 101 and 101 ' on each side of the frame;

- ROV panel 102 with ROV valves, gauges and receptacles;

- Docking plate 103 for holding component;

- Cage assembly supporting docking plate 108;

- Pull-in cylinders 104 and 104';

- Pitch cylinders 105 and 105';

- Rotation cylinder 106;

- Hang off unit 107;

- Docking cone 109.

Figures 2 and 3 are detailed view of the docking plate 103 and cage assembly 108 respectively. Aspects of the AIA frame are described further below, with respect to the procedure for landing a component on a riser. Example dimensions for the AIA apparatus depicted in Figures 4 to 13 are given in the table below:

Gripper unit (GU) apparatus:

An exemplary embodiment of a gripper unit (GU) apparatus 200 is illustrated in Figures 14-20. The GU should be sufficiently light-weight to allow an ROV to carry it from a basket to the worksite without crane assistance. As load is applied to the GU, the slips segments 201 move upwards and inwards relative to the body of the unit 204 and the teeth protrude slightly into the pipe surface 203. The ultimate capacity is limited by the shear strength across the number of teeth activated. The GU also comprises a cap 205 shaped so as to interface with the docking cone 109 of the AIA frame.

As the slips will not engage around the complete circumference of the pipe, this will ensure that all alignment reaction forces introduced into the pipe will be on the part of the pipe that is circumferentially supported by the slip segments. The initial activation of the slip teeth onto the pipe is by mechanical closing of the slip carrier. This is only required to hold the weight of the unit. Thereafter the slips are self-activating. The GU has slips with longitudinal as well as transverse teeth. The longitudinal teeth will determine the torsional capacity of the GU during the subsequent rotational alignment. Some torsional forces may be introduced by the flexible, but these are assumed to be low.

To eliminate the need to lock the GU onto the riser pipe while suspended from the crane, with associated risk of introducing vessel dynamic forces to the riser, a light weight unit that be launched with the ROV is proposed. The weight of the concept unit is about 50 kg.

Key aspects of the GU include:

- Light weight: ROV handling only

- Nearly full circumferential pipe support

- Self-activating slips

- Reaction forces taken over long length

- Teeth profile qualified by DnV, no fatigue issues after gripping

- Pull test to ensure initial activation

- Positive disengagement of slips

The GU has slips with longitudinal as well as transverse teeth. The longitudinal teeth will determine the torsional capacity of the GU during the subsequent rotational alignment. Springs 202 in the GU ensure that the slip segments will always be forced inwards (towards the pipe). The springs will always try to pull the GU body downwards relative to the slip segments. When the GU body is pulled downwards relative to the slip segments, the slip segments will be forced inwards towards the pipe. Thus the GU will at all times hold onto the pipe. In the event that the GU is subjected to a large upwards force, it might release from the pipe, but once the force is removed the GU will grip back onto the pipe due to the force provided by the springs. From a risk point of view this is a significant advantage as otherwise (i.e. without springs) the GU might fall off the pipe.

The hardened teeth bite into the pipe surface. The tooth profile from the DnV qualified clamps will be utilized. These have been checked against RP-F1 13 to ensure that the marks left on the pipe surface shall not initiate subsequent fatigue damage. Example dimensions for the GU apparatus depicted in Figures 14-20 are given in the table below:

Figure 19 is a close-up view of the encircled region (labelled 250) in Figure 17, where 206 is a spring lower shell; 207 is a spring support; 208 is a screw (e.g. M8x16); 209 is a torsion spring; and 210 is a screw (e.g. M6x40). Figure 20 is a bottom view of the GU apparatus. Figures 21 and 22 show an installation tool 260 for installing the GU apparatus 200 on a riser, where 21 1 is a buoyancy aid; 212 is the installation tool frame; 213 is a 6-line hot stab; 214 is a flange with cylinders for activation; 215 is a left running tool gripper; and 216 is a right running tool gripper.

Other aspects of the GU apparatus as illustrated in Figure 16 include: upper half shell 217; locking bolt 218; bottom half shell 219; and disc springs flange 220. Outline of procedure for landing a component on a riser:

In the following, an exemplary method for landing and installing a component (e.g. a flange adaptor) on a riser is outlined. The main method steps are depicted, in sequence, in Figures 23 to 39. It should be noted that certain steps may be omitted. Furthermore, although the below steps are directed towards a riser which is supported by a riser tower, one skilled in the art will appreciate that the method is also applicable to a riser which is independently suspended. 0) Perform initial cutting of the riser pipe 301 ; secure the lower section of the riser pipe once cut in a cofferdam provided on the riser tower 302; cut the piggyback straps above the cutting point to allow the bottom end of the upper section of the riser pipe to be moved out from the riser tower; install a riser jacking tool 303 (RJT) on the riser tower, above the cut; jack the bottom end of the upper section of the riser pipe (hereafter referred to as the "riser pipe") outwards from the riser rower; cut a 2 metre long section from the end of riser pipe; remove pipe coating; and prepare end of pipe.

1 ) Perform a pre-survey to determine the extent of the lean of the riser tower and identify the heading of a 3 metre long straight section at the bottom of the riser pipe. The readings from a hydro-acoustic position reference transponder and high-precision acoustic position transponder on the riser tower buoyancy tank and remotely operated vehicle should be sufficient for the accuracy required. If the heading identified is within +/-20 degrees error margin, the rotation in the gripper unit (GU) apparatus 200 can correct for it.

2) Perform initial testing of all systems on the deck of the vessel.

3) Launch from the vessel the tool basket containing the GU apparatus 200 and a subsea marker. Alternatively these may be launched with the ROV 304. It should be ensured that the buoyancy tank and dynamic risers are avoided to prevent damage thereto.

4) Mark a 12 o'clock position 1 .25 m from the end of the riser pipe. Also mark ROV grabber exclusion zones. The RJT may be retracted slightly to allow the ROV to grab onto the riser tower and be in a more stable position when performing the marking. The distance from the riser pipe end has a tolerance of +/- 50 mm that can be corrected pull-in cylinders on the AIA frame 100. The distance is measured from the riser pipe end with a prefabricated L-shaped piece of tubing with magnets attaching it to the pipe, while the mark is made with the ROV. The mark is made with a subsea 'crayon' type stick. The IKM Technique Subsea Marker (http://www.ikm.com) may be used, for example. Care should be taken to ensure that the lower 250 mm of the riser pipe, and the 250 mm just below the GU apparatus are not be damaged by the ROV 5- function manipulator, as these areas are the primary and contingency sealing areas for the flange adaptor 306.

5) Grip onto the allowed grabbing zone on the pipe with the left hand ROV 5- function 'grabber'. Install and activate the GU apparatus 200 using the installation tool 260 operated by the ROV's 7-function manipulator, as depicted in Figures 23-27. The GU apparatus is installed with the open slot perpendicular to the pipe bending plane. The activation is by turning an ROV handle clockwise using the wrist rotate function. The pitch of the threaded connection that activates the slips should be selected to ensure sufficient grip based on an applied torque of 100 Nm, for example.

6) Perform vertical pull test on GU apparatus using the ROV. Pull between the left hand grabber and the right hand 7-function manipulators. The left hand grabber may be holding onto the riser pipe below if possible, or the RJT may be used to bring the riser pipe closer to the riser tower thereby allowing the ROV to grab onto another riser tower pipe. This verifies initial engagement of the GU apparatus towards the riser pipe, and starts weight setting the teeth into the riser pipe wall. The vertical pull test is limited by the force capacity of the 7-function manipulator, but is only required to prove initial activation to support the weight of the GU apparatus itself.

7) Check the elevation and heading of the installed GU apparatus. A vertical allowance for incorrect installation may be +/- 50 mm as measured from the riser pipe end. Correct installation within this tolerance is deemed to be uncomplicated to achieve with a prefabricated L-shaped measuring tool.

8) Rig the AIA apparatus and connected flange adapter and flexible riser for deployment by the vessel crane. The in-water centre of gravity may be calculated to allow a 45 degrees deployment angle with the GU apparatus docking unit aligned with the riser pipe axis. In addition, the AIA apparatus may have an adjustable lifting point, to allow adjustment on site for the correct suspended angle.

9) Deploy and lower the AIA frame and flexible riser to the working depth. The net resultant force from the flexible riser will depend on whether the other end of the flexible riser is suspended from a second crane or winch. The lifting points will be designed in accordance with DnV Offshore standards (available at: https://rules.dnvgl.com/servicedocuments/dnv). 10) Move the AIA apparatus towards the riser pipe between the RJT and the GU apparatus, preferably keeping the load (including the AIA apparatus) under active heave compensation, Figure 28. The AIA apparatus docking slot for the riser pipe has guide plates to facilitate guiding onto the riser pipe.

11 ) Guide the AIA apparatus docking slot onto the riser pipe with the ROV and lower the AIA apparatus until the lift rigging 305 is fully slack, Figures 29-32. Disconnect the lift rigging, Figure 33. The docking slot can slide up and down the riser pipe including the three layer polypropylene coating. The amount the docking slot can slide is limited by the distance between the RJT and the GU apparatus. The docking cone is pre-adjusted so that its axis is roughly aligned with the riser pipe axis at the moment of docking. When being lowered, the hydraulic pitch cylinder on the AIA apparatus may bypass the hydraulic fluid to an accumulator tank to reduce the bending moment introduced into the riser pipe when the crane is lowering the AIA apparatus, flange adapter and flexible riser to a position where the loads become suspended from the riser pipe. The GU apparatus centralizes the docking cone as well as guiding it into the correct axial and rotational position. Some torsional forces may be introduced by the flexible riser, but these are assumed to be low. Maximum allowable landing speed will be determined by considering bending stresses induced in the riser pipe and radial reaction point loads in pipe wall. The self-activation property of the GU apparatus will create radial loads circumferentially on the riser pipe. Installing the AIA apparatus at an angle reduces risk of induced loads from the crane onto the prepared riser pipe end.

12) Grab onto the ROV panel of the AIA apparatus and close the 'float' function valve, Figure 33. The float function is the bypass to the accumulator from the pitch cylinder, introduced to reduce bending moments in the riser pipe during landing, as well as reducing the bending moments on the extended pull-in cylinders. The ROV panel is designed with a grabber bar on the left side to provide a fixed position for the ROV. The grabber bar is used with the ROV's left 5-f unction 'grabber' arm, and the stab insert and valve operations are carried out with the right hand 7-function manipulator.

13) Insert 3 hydraulic 6-line stabs into receptacles on the ROV panel on the AIA apparatus. FMC/Oceaneering stabs may be used. All stabs may be delivered with D- handle as well as 'fishtail' handle for parallel 3-finger jaw. 14) Operate the pitch cylinder to lift the flange adaptor 306 until it is axially aligned with the riser pipe, Figure 33. The pitch cylinder may be designed to provide up to 20 degrees of pitch. The pitch cylinder may be sized so that it cannot provide enough force to overstress the riser pipe. 15) Using, for example a level indicator, check that a plane through the axis of the two pull in cylinders is at 90 degrees to the riser bending plane. The ROV panel may have a level gauge to assist the visual indication that the AIA apparatus is correctly aligned. 16) If the angle is offset, operate the rotate cylinder to achieve axial alignment.

17) Stab the, for example Gisma, electrical/signal connector to the AIA apparatus. Tronic connectors may also be used. 18) Increase the hydraulic pressure in the pull-in cylinders of the AIA apparatus until the AIA apparatus starts lifting, Figure 34. Use visual feedback through dedicated camera and proximity sensors to confirm alignment. The AIA apparatus/flange adapter may have two cameras, 90 degrees offset with a sighting line along the connector axis. The cameras are used to provide visual verification of alignment to the operator. Furthermore, proximity sensors are installed on the flange adaptor to assist with alignment.

19) Check alignment just before entry of the riser pipe into the flange adaptor. Operate pitch, rotate, and pull-in cylinders to align. 20) Keep lifting the AIA frame using the pull-in cylinders until the riser pipe is fully bottomed out in the flange adaptor. Monitor sensor feedback can be used to monitor this part of the installation. The operator may operate the two pull-in cylinders independently from each other for fine alignment. The operator should continuously monitor the alignment by camera and pressure readings. The pressures should be kept low, only 2-5% above the necessary pressure to lift the suspended weight. If the pull-in stops, that is an indication of jamming and without increasing the pressure, the primary method to resolve it is to identify and lift only with the lowest (most extended) cylinder. The tilt and rotate function of the AIA apparatus can also be used for fine alignment at this stage. The two hydraulic circuits for the pull-in cylinders can also be operated in parallel after a certain engagement has been achieved, utilizing the flange adaptor's self-aligning capability. This may save a small amount of operation time. The cylinder interface to the AIA apparatus can be built with a small degree of flexibility, by rubber bushings or springs. This utilizes the self-alignment capability of the flange adaptor, and may reduce the number of jamming incidents and simplify the task for the operator.

21 ) Increase the holding pressure in the pull-in cylinders to hold the riser pipe firmly to the flange adapter abutment face. Upon activation of the flange adapter when the balls make initial contact with the surface of the riser pipe, the activation will tend to separate the end of the riser pipe from the abutment face. The pull-in cylinders are dimensioned to counteract that force.

22) Activate the flange adaptor. The 1500 bar pressure for the tensioners is achieved by integrating a hydraulic intensifier on the connector body. The sensors on the tool are linked up to the ROV skid, where the signal from each sensor is multiplexed onto an RS485 serial communication to the topside control unit. Visual indications provide backup for the sensors in the connector. 23) Perform a seal test. The seal test may be carried out with hydraulic oil. The volume to be tested is small and only a very small volume is required to increase the pressure to 350 bar. A very small volume would then be released to the sea upon completion of the seal test. A hydraulic intensifier may be used to provide the pressure for the seal test. 24) Disconnect the hydraulic stabs between the AIA apparatus and the flange adapter.

25) Cut or pull off the sensor cables between the AIA apparatus and the flange adaptor. For cutting, the ROV cable cutter may be used.

26) Unlock the locking-bolt with the ROV handle on the AIA apparatus, and extend the pull-in cylinders approximately 500mm, Figure 35. Ensure the AIA apparatus is fully undocked from the flange adaptor. Monitor separation between the docking cone and GU apparatus.

27) Using the pitch cylinders, start pitching the AIA apparatus out, away from the riser pipe, Figure 36. When the flange adaptor and flexible riser have been disconnected from the AIA apparatus, the AIA apparatus can be tilted outwards by a larger angle without inducing a large amount of stress into the riser pipe. This creates sufficient clearance to recover the AIA apparatus without danger of impact with the flange adaptor.

28) If required, operate the rotate cylinder on the AIA frame back to neutral position to align the key-slots in the docking cone.

29) Operate the pitch cylinder until maximum distance between the AIA apparatus and the flange adaptor is achieved. Disconnect the ROV stabs. Note that an angle greater than 20 degrees can now be achieved as the weight of the flange adaptor and flexible riser has been removed from the AIA apparatus.

30) Lower the crane with a forerunner and hook onto a lift point of the AIA apparatus for recovery of the AIA apparatus back to the surface, Figure 37. The centre of gravity (COG) of the AIA apparatus will by this point have changed significantly, due to disconnection of the flange adaptor, hence a separate lift point may be used. The lift point is designed for ease of ROV hook connection

31 ) Lift the AIA apparatus clear of the GU apparatus. 32) By movement of the vessel and/or crane boom, move the AIA apparatus clear of the riser pipe by a safe distance. The AIA apparatus may also be guided with assistance from the ROV. What constitutes a safe distance may be dependent on weather and vessel station-keeping capability, as well as actual current.

33) Recover the AIA frame back to the vessel deck.

34) Deactivate and recover the GU apparatus to the tooling basket and subsequently recover to the vessel deck.

Figure 39 shows the riser pipe with the installed flange adaptor 306 after completion of the method.

Although the invention has been described in terms of preferred embodiments as set forth above, it should be understood that these embodiments are illustrative only and that the claims are not limited to those embodiments. Those skilled in the art will be able to make modifications and alternatives in view of the disclosure which are contemplated as falling within the scope of the appended claims. Each feature disclosed or illustrated in the present specification may be incorporated in the invention, whether alone or in any appropriate combination with any other feature disclosed or illustrated herein.